Process Control
CONTENTS
1. Introduction
2. Models for Control
3. Process Identification
4. Analysis of Transfer Function Models
5. Controllers and Analysis of Closed-loop Transfer Function
6. Controller Tuning
7. MIMO Control Concepts
8. Model Predictive Control
9. Case Studies
Introduction
The concept of feedback was introduced to address these concerns and the
entire control system is usually designed so that the overall closed-loop
system (including the controller) is able to achieve the following six
objectives: safety (overall process is stable), environment protection (the
process output obeys the environment regulations), equipment protection
(behavior of the closed-loop system does not result in damage to the
equipment), high production rate, product quality, and profitability.
Usually, this profit function is notionally optimized through heuristic
knowledge or through a formal mathematical approach.
• Single-Input-Single-Output and
Multi-Input-Multi-Output Controllers
• The manipulated and controlled variables that participate in the controller
are depicted in Figure 1. In the figure, the controller chooses values that the
manipulated variables need to attain given the setpoints that the controlled
variables are expected to follow. One option at this point is to define a
controller that manipulates all the variables (m1;…..; mr; :…. ; mm) at the
same time to ensure that all controlled variables are maintained at their
respective
Overall control structure: c1; …… ; cn controlled variables and
m1; ……; mm manipulated variables
First, analysis and design of multivariable controllers is much more
complex than designing and analyzing single loop controllers. The theory
for design of multivariable controllers was not as well developed, a few
decades ago, as it is now. Hence, process plants are operated with single-
input-single-output (SISO) controllers, and they work fine for about 90% of
all control loops in the process industry.
Even with advances in multivariable control theory and practice, SISO
controllers are still very popular in process industries.
Consider a multivariable controller which has 40 inputs and 40 outputs.
Suppose that something goes wrong with this controller and it needs
servicing; this would mean that all 40 variables will go out of control for a
while, which would not be desirable. However, a single loop controller, if it
needs servicing, takes only one variable out of control at a time.
The third reason why SISO controllers work quite well is because simple
advanced concepts can be easily incorporated into the SISO controller
framework.
Block diagram representation of multivariable problem with
Overall 2 × 2 multivariable control problem
SISO controllers